truflow operation and maintenance manual€¦ · “see what you save” introduction thank you for...

Truflow Operation and Maintenance

Manual

___________________________ Spring Air Systems Inc., Oakville, Ontario

Phone (866) 875-4505, Fax (905) 338-0179, [email protected] www.springairsystems.com

January 2008

TRUFLOW Maintenance and Operation Manual Table of Contents

Introduction 1 Quick Start 2 One Kitchen Operation 2 Multiple Kitchen Operation 4 What is the TRUFLOW? 5 What is a J-Couple? 5 What is the Touchscreen? 6 What is the Variable Speed Drive (VFD)? 7 User Setup Login 10 User Setup Logout 11 User Setup Screen Overview 11 User Setup Screen Button Functions 12 Setting Time and Date 12 Energy Goal Reduction Setup 12 Time to Dashboard 13 Setting the Automatic Opening and Closing Times 13 Entering the Message Center Text: 14 Entering the Company Name 14 Secondary Setup Button 14 Changing the Kitchen Names 15 The Diagnostic Screen 16 Common Error (fault) Messages 17 The Report Screen 18 KES Users Screens (Optional) 20 Odor Spray Unit (Optional 21 Truflow Wash Screens (Optional) 21 Truflow Touchscreen Startup Report 24 Appendix A: Truflow stainless steel enclosures dimensions 29 Appendix B: Remote Wiring 30 Appendix C: PXR Factory Setup 34 Appendix D: PXR Sensor Fault Operation 35 Appendix E: Tele Factory Drive Terminal Schematic 36 Appendix F: Hazardous Warnings 37 Appendix G: Good Wiring Practices 38 Appendix H: Grounding 39 Appendix I: Starting the Drive Manually 40 Appendix J: Accessing the Drive Program Menu 41 Appendix K: Factory Drive Program Parameters 42 Appendix L: Drive Maintenance and Trouble Shooting 43 Appendix M: Wireless Remote Option 48 Appendix N: J-Couple Remote Factory Supplied Cable 51 Appendix O: Code Changes 52 Appendix P: Testing Truflow After Running for 30 seconds 53 Appendix Q: Adding and Removing Users and Changing Passwords. 54 Appendix R: Truflow Factory Setup 55

January08

Spring Air Systems Maintenance Manual January 2008 “SEE WHAT YOU SAVE”

1

Finished Ceiling

Exhaust Duct

Exhaust Fan

J-COUPLE

Appliance Lineup

Finished Floor

Exhaust Hood

Touchscreen

Roof Deck

185

Truflow Maintenance Manual “SEE WHAT YOU SAVE”

Introduction Thank you for purchasing a Spring Air Systems Truflow Energy Controller. Truflow provides precise, real-time measurement allowing you to effectively manage your team to reduce energy use. Truflow is the most economical and efficient kitchen ventilation energy management system available. The average commercial kitchen exhaust system operates at 100% capacity for 12 to 18 hours per day, blowing thousands of wasted energy dollars out the roof! Truflow measures heat from the appliances and automatically adjusts fan speeds throughout the day, giving you the precise amount of exhaust at all times. Truflow monitors ventilation system efficiency relative to your utility costs, in real-time, so that you can manage your kitchen to take advantage of off peak times by turning down appliances. Setting an energy reduction goal reduces your utility costs even more!

You have the ability to increase the exhaust volume to 100% at any time. Because you control it, overrides are kept to a minimum to maximize energy efficiency. The override system runs for an adjustable timed period of 15 minutes and can be activated at the hood or via a remote control. Truflow not only saves you money on energy expenses it can also help extend the life of your equipment by demanding exhaust only when it is really required. Truflow can be specified on new hoods or can be retrofitted on your existing hoods. Since the panel can be hood mounted or wall mounted, it allows you many convenient options of where to locate the panel and wireless remote unit. Truflow is Internet accessible, so it is ideal for multi-unit management. The TRUFLOW system reduces the amount of air exhausted from the kitchen to match the amount of cooking. As more appliances are used, the exhaust and supply volume increase, as less appliances are used the exhaust and supply volume decreases.

TRUFLOW DASHBOARD

TRUFLOW Kitchen Figure 1


2

Quick Start Prior to Quick Start:

1. The commercial kitchen hood(s) exhaust fan(s), and supply fan(s) have been installed in accordance with all applicable national and local codes.

2. The interconnection wiring and cables have been completed in accordance with all applicable national and local codes.

3. The commercial kitchen surface fire suppression system has been installed per NFPA code and tagged.

4. An authorized Spring Air Systems Inc. service technician has been to site to provide a factory startup service and tagged the panel.

5. The circuit breaker is on and providing 120V/1/60 power to the panel. One Kitchen Operation:

Truflow dashboard powered on with one kitchen connected to Truflow panel.

Press the icon on the left to turn on the canopy lights Press the System Control icon to change to the Power screen.

Press the Hand icon to manually operate the kitchen on/off operation The Hand icon should have a white border while activated. If it does not, press the Hand icon again. Press the Kitchen Start icon. The Kitchen Start icon has a white border while the kitchen is operating.

Press the summer/winter switch depending on the time of year.

Summer Winter

The Truflow will automatically change to the Dashboard display. The kitchen is now operational.


3

Let’s take a closer look at the DASHBOARD for Kitchen 1

This is the Kitchen1 DASHBOARD,

displaying the Kitchen 1 operational parameters. The Kitchen 1 name can be changed through the setup screen with a password.

The Efficiency vs. Seconds DASHBOARD graph indicates kitchen operation is green and

108% efficiency. Kitchen1 is 8% over the targeted energy savings.

The exhaust fan volume is 1100CFM at 108% efficiency. The outside temperature is 66F.

The canopy lights are off. When the canopy lights are on there is a white border around the Light icon.

To override the Truflow press the Efficiency button. An Efficiency button crossed out will appear and the Kitchen1 operation will drive to 100% exhaust. The override time is adjustable from the O/R button on the Power screen.

Press this button to switch to System Control screen.

Press this button to switch to Error Status screen. Press this button to switch to Report screen.

Press this button to switch to Setup Screen. This screen is accessible only with a password.

The Company Name and Message Center are accessible from the Setup Screen with a password.

The date and time of day are displayed at the top right of the DASHBOARD screen. Both the date and time are adjustable

from the setup screen with a password.


4

Multiple Kitchen Operation The DASHBOARD for a multiple kitchen Truflow displays the Kitchen Name, Efficiency, Exhaust CFM and the Canopy light switch for each kitchen connected to the Truflow. The example dashboard to the left has three kitchens connected to the Truflow.

Kitchen Name Efficiency of Kitchen

Operating Exhaust CFM for Kitchen

Pressing the Kitchen Name, Efficiency or Exhaust CFM button for any Kitchen displayed changes the screen display to the Individual Efficiency graph of

the specific kitchen. The Efficiency button for Kitchen3 was pressed from the DASHBOARD screen to display the screen shown on the left.

Press the System Control button to change to the Power screen.

For a description of the functions for each button for each kitchen see the ONE KITCHEN OPERATION above. The button functions are identical to the ONE KITCHEN OPERATION for each extra Kitchen.

Adjusting the Override Time:

From the Power screen press the O/R button and the Override timer screen will appear.

Press the 15 box and the Truflow numerical keyboard appears.

Type the new Override value and press Enter to save.

Press the OK button to return to Power screen


5

J-Couple

Kitchen Hood

ExhaustFan

drive signal to motor

CAT5 Variable Speed

Drive signal to motor

CAT5 Variable Speed

SUPPLY FAN

What is TRUFLOW? The TRUFLOW Energy Management Controller has been designed to change kitchen exhaust forever. TRUFLOW will automatically reduce the exhaust and supply air into the kitchen whenever appliances are not used at full capacity. When the appliances are not used and the heat is turned down or off TRUFLOW automatically senses the reduction and decreases the amount of exhaust and supply to match exactly what is happening under the exhaust hood. The TRUFLOW duct mounted J-Couple monitors the exhaust temperature, which fluctuates based on the amount of appliances operating under the exhaust hood. As the amount of cooking increases the exhaust duct temperature rises and reaches an equilibrium temperature during each hour of the day. TRUFLOW automatically modulates the exhaust and supply to suit the actual cooking operation at any given time during the cooking day.

The Truflow System Components: What is the J-Couple? The J-couple is mounted in the center of each exhaust hood duct collar. The J-couple threads into a UL/ULC listed hood penetration fitting. The J-couple wiring is terminated in a factory supplied J-Box. Each hood duct collar connected to an exhaust fan connected to Truflow has a J-couple. The J-Couples are wired in series, connected together with factory supplied Mini-clips from the last duct collar to the Truflow panel.

J-box

J-couple

Exhaust Hood

Exhaust duct collar

UL/ULC duct penetration fitting

J-couple Mini-Clip connector to the Truflo panel

J-Couple hood duct collar mounting Figure 3

TRUFLOW System Components 1. J-Couple. 2. Touchscreen. 3. Variable Frequency Drive (VFD)

Figure 2


6

What is the Touchscreen? a. Dashboard

The Touchscreen is the heart of the Truflow, integrating the J-Couples and VSD to provide a complete commercial kitchen Energy Management Controller. The Touchscreen includes five functional screens: Dashboard,

System Control, Alarm Status, Reports and Setup & Diagnostics. Press the Dashboard icon to view the Dashboard. The Dashboard includes a graph that represents the energy use throughout the day. The graph provides energy consumption measured against a reduction goal. The Dashboard tells the kitchen staff whether the system is exceeding the goal or not.

EFFICIENCY, Exhaust CFM, outdoor temperature is also displayed. The outdoor temperature measurement allows for real-time energy savings reports directly from TruFlow!

b. System Control The System Control displays components of all exhaust systems controlled by TruFlow including Hood lights, Fan on/off switch, Summer/winter switch, and Override timer.

c. Alarm Status The Alarm conditions are displayed for all systems controlled by TruFlow. Touch the single bell icon to clear selected alarm. Touch multi-bell icon to clear all alarms This action does not FIX the problem, it simply records

that an alarm or alarms have been acknowledged. A Service Company must still be called!

e. Reports

TruFlow can record a full year of data. The standard reports provided are seen on the Report screen. % Time Exceeding Goal is the key energy management report.


7

Knockouts at top of Touchscreen Panel Figure 5

PANEL DIMENSIONS

14.00

10.00

2.00

14.00

TOUCHSCREEN

MOUNTING BRACKET

Touchscreen Wall Mounted Panel Figure 4

f. Setup & Diagnostics

The main system setup display allows entry of reduction goal, primary message center text, and company or restaurant name.

The power of TruFlow lies in the setting of an energy reduction goal. The goal represents a target % reduction of past utility costs (hourly or monthly rate). Goal can be reset at any time to maximize energy efficiency and savings! Gas and electricity costs can be entered at any time as monthly or

hourly rates. Truflow can measure gas in joules or therms by selecting Imperial or Metric Units The User may set daily or weekly operating times. The Diagnostics screen provides a comprehensive service screen to quickly diagnose problems. The screen can be accessed via Internet for remote service by Spring Air directly or Authorized Service Technician Touchscreen Panel Top Knockouts list from left to right.

34

CO

ND

UIT

KN

OCKO

UT

CABLE

CO

NN

ECTO

RS

VFD

CAT5 C

ABLE

OU

TD

OO

R T

RAN

SD

UCER

INTERN

ET C

ON

NECTIO

N

AU

X2

LV4

LV3

KIT

CH

EN

J-C

OU

PLE

21

LV1

LV2

AU

X1

CO

ND

UIT

KN

OCKO

UT

CO

ND

UIT

KN

OCKO

UT

TOP OF TOUCHSCREEN PANEL • Kitchen 1 J-Couple female plug. • Kitchen 2 J-Couple female plug. • Kitchen 2 J-Couple female plug • Kitchen 2 J-Couple female plug. • VFD CAT5 plug for all drives. • Outdoor Temperature Transducer supplied by Spring

Air installed by contractor. • Optional Internet connection. • LV1 – Optional CAT5 to 1st KES • LV2 - Optional CAT5 to 1st KES • LV1 – Optional CAT5 to 1st KES • LV2 - Optional CAT5 to 1st KES • LV3 – Optional CAT5 to 2nd KES • LV4 - Optional CAT5 to 2nd KES • AUX1 – Optional CAT5 to water wash panel • AUX2 – Optional CAT5 to SAT to SFT makeup air


8

What is Variable Frequency Drives (VFD)? The variable speed drives for the exhaust and/or supply fan can be located in a stainless steel enclosure adjacent to the Touchscreen panel or anywhere else in the building.

• When the makeup air unit is direct gas fire (like the Spring Air Systems SAT unit) the supply

drive can be located in the makeup air unit control panel or with the exhaust fan drive(s) in a separate enclosure. (SV Type)

• When the make up air unit is indirect gas fired (like the Spring Air SFT unit) the supply drive is not required. The Touchscreen panel sends a 4-20milliamp signal through a CAT5 cable to the makeup air unit modulating bypass damper. (SC Type)

A CAT5 cable is connected to each drive in series from the Touchscreen panel. The first cable connects from the Touchscreen to the first drive “Y” connector. The 2nd drive cable connects from the first drive “Y” connector to the 2nd drive “Y” connector. Each drive is connected in series. When the Touchscreen is initially activated the communication software starts all the exhaust and/or supply drives at 100% capacity for 20 seconds for each kitchen. After the initial 20 seconds, the exhaust and/or supply drives ramp up and down depending on the signal from the J-couple(s). As the exhaust volume increases and decreases the supply volume increases and decreases in unison to maximize energy savings. The supply unit motorized damper end switch can also be interlocked to the Touchscreen such that the end switch must close to start the supply fan drive operation. The drive changes the AC frequency to the exhaust motor between 18Hz and 60Hz.

VSD front Figure 6

VSD open front Figure 7

VSD front display Figure 8


9

Remote wiring to VSD Figure 11

VSD terminal locations Figure 10

Multiple VSD control connections Figure 12

The figure 13 indicates where the three-phase power supply from the breaker panel connects to terminals R/L1, S/L2 and T/L3 on the drive. The three-phase power from the variable speed drive to the motor connects to terminals U/T1, V/T2, and W/T3. The lowest possible exhaust volume is 30% of the maximum to meet the existing code and ensure that the products of combustion are always adequately exhausted. At 30% exhaust the drive is operating at 18HZ.

VSD frame sizes and EMC mounting plate Figure 9


10

User Setup Login

From the DASHBOARD screen press the Setup icon.

Press the Login icon.

Press the text box beside Name. A typewrite pad appears. Enter the login name. The login name is case sensitive. The CAPS key is on

automatically. If you do not know your login name and password call Spring Air Systems. After the login Name is complete press the Enter key. The screen will return to the Login screen. Press the white area beside Password. The keyboard screen appears again. Type the login password. The password is also case sensitive. When the login Password is complete press the enter key. The screen will return to the Login screen.

Press the UNLOCK icon. Press the word Close to close the login box. You have completed the login.


11

Logout After you have completed the user setup, ensure that you logout of the setup so that your setup entries are saved and cannot be changed accidentally by the kitchen staff.

Press the Setup screen button.

Press the lock.

Press the lock again. You are now logged out. Once you have logged out there is no longer access to any setup screen. All settings are saved until you login again and change them.

User Setup Screen Overview

Press to set Date and Time on DASHBOARD

Press to setup annual energy savings goals for Truflow Kitchen Operation Press to setup automatic Kitchen open and closed operating times.

Press to change message on bottom of DASHBOARD screen. Press to change company name on top of DASHBOARD screen. Press to change the time before Truflow switches from any screen back to DASHBOARD screen.

Press Security button to add or remove users and their passwords. Press Setup icon to view current drive information.


12

User Setup Screen Button Functions Setting Date and Time

Press the box beside the date and time to change the date and time. A popup screen appears. Enter the new

date and/or time.

Energy Goal Reduction Setup

Press the dollar icon and the Goal Reduction Screen appears.

Press the Reduction Goal box to select a goal reduction for the Kitchen operated by the Truflow panel. A Reduction Goal keyboard appears. Enter the Reduction Goal by touching the keypad and press the Enter button. Gas Cost: Press the Gas Cost box and enter the cost of energy for the kitchen based on $/thm ($/1,000,000 Btu’s) using the pop up key board.

A Gas Cost keyboard appears. Enter the Gas cost by touching the keypad and press the Enter button.

Electricity Cost: Press the Electricity Cost box and enter the cost of electricity for the kitchen based $/KWH using the pop up key board.

An Electricity Cost keyboard appears. Enter the Electricity cost by touching the keypad and press the Enter button Demand Electricity Cost: If the commercial kitchen operation pays extra for electricity during peak periods of the day select the Demand Electrical button. Enter the higher electrical rate at peak periods in the Demand Electricity cost box. Press the 0.00 in the box and a Demand Electrical Cost keyboard appears. Enter Demand Electrical cost by touching the keypad and press the Enter button


13

Demand Electricity Cost: Enter of the time of day the Peak electrical rate starts.

Enter the time of day the Peak electrical rate ends

For calculation of the energy cost select whether the kitchen is air conditioned with DX or chilled water cooling. The cost of cooling the fresh air into the kitchen will be added to the kitchen energy during the summer months.

DX Cooling Option: No DX or chilled water cooling of kitchen fresh air.

Press the Button when there is DX or Chilled Water cooling of kitchen fresh air.

Press the Setup button again to return to the primary set up screen

Time to Dashboard: Press the 20 in the Time to dashboard box to select the number of seconds before the Truflow switches back to the DASHBOARD screen. If you want the Truflow to remain on the last screen viewed set the number to 0.

Setting the automatic Opening and Closing Times:

Select the time for the kitchen exhaust system to start for Monday through Sunday. Select the time for the kitchen exhaust system to stop for Monday through Sunday. Press the next page button to set Friday, Saturday and Sunday.

If the Kitchen does not operate on a specific day, make the start and stop time the same on that day and the kitchen exhaust system will not operate that day.


14

Entering the Message Center Text:

Press the words Message Center to open the Message Center Text keyboard. Using this keyboard, enter the daily message for the kitchen staff. When you have completed the message press Enter.

Entering the Company Name:

Press the words Company Name to open the Company Name Text keyboard. Using this keyboard enter a kitchen or restaurant name. This is important if the Truflow will be accessed through the Internet. This name will help distinguish one Truflow panel from another run by the same organization. When you have completed the kitchen or restaurant name press Enter

Secondary Setup Button

Press the Secondary Setup button to view the kitchen room temperature, the outdoor air temperature and the number of kitchens connected to the Truflow. The Truflow on the left has two kitchen connected, one called Main and the other called Prep. Press the Main Kitchen bar to view all fan drives connected to the main kitchen. Press the Prep Kitchen bar to view all fan drives connected to the prep kitchen fan drives.


15

Viewing Drive Parameters After pressing the Main Kitchen and/or Prep Kitchen bar the drive parameters can be viewed for that specific kitchen. The user can not change any parameters. The user can view Motor Frequency, Current, Motor Torque, Line Voltage, Thermal State, and Motor Power. In the example on the left the Prep Kitchen has two exhaust fans. Exhaust is first exhaust fan parameters.

Press the Right Arrow icon at the top right of the screen to view the second exhaust fan parameters. (2Exhaust)

Press the Left Arrow key once to return to the first exhaust fan parameters.

Press the Left Arrow key again to return to the Secondary Setup Screen.

Changing the Kitchen Names:

User must first Login to the Truflow. On this Truflow there are two kitchens operating: Kitchen 1 and Kitchen 2. Press the Kitchen 1 box to change the screen to the efficiency graph screen.

Kitchen 1 efficiency graph screen

Press the Kitchen 1 word at the top left of the screen

The Truflow keyboard appears. Type the name of the kitchen using up to 10 characters. Press the enter key when you are done. Return

to the DASHBOARD and press the Kitchen 2 box to change the screen to the Kitchen 2 efficiency graph. Repeat as above.


16

THE DIAGNOTIC SCREEN

From the DASHBOARD press the Diagnostic button. The Diagnostic screen includes a record of all faults during the operation of the Truflow. Acknowledge All Faults button Acknowledge Fault button Scroll Up one line

Scroll Down one line Scroll Up one page Scroll Down one page Run diagnostic script when available.

Clear Com or Comport error.

Errors When an error occurs the screen will change to red with a yellow exclamation mark. Touch the screen anywhere and the diagnostic screen appears. The screen displays the latest error message including the date, time, state and whether the error has been acknowledged. Most errors are self explanatory.

Press this button for additional explanation. When available, a popup screen appears with additional information.

Whenever there is a COMM PORT or COMM error or fault, the Clear Error On Drive button must be pressed after the fault has been corrected to resume normal operation.


17

Common Truflow Error (fault) Messages a) Drive(x) Motor Overload/Over-speed fault. Motor overload setting incorrect or RPM too high. b) Drive(x) Exhaust over-current fault. Running motor amp too high. c) Drive(x) Impending Short Circuit. Possible dead short at fan(x) motor soon. d) Drive(x) Motor short circuit fault to earth. Dead short at fan(x) motor e) Drive(x) Line supply over-voltage fault. Input voltage source to drive too high. f) Drive(x) Line under-voltage fault. Input voltage source to drive too low. g) Drive(x) Supply phase loss fault. Input voltage source to drive has lost a phase. h) Drive(x) Drive over-heating fault. Drive(x) is overheating. Shut off fan. i) Drive(x) Internal Fault. Drive(x) has internal fault that will not allow drive(x) to operate from

Touchscreen panel. j) Drive(x) MODbus Communication fault. Drive(x) connected to the Truflow is not

communicating with Truflow. k) Drive(x) External Fault. Drive(x) is faulty. l) Drive(x) Brake control fault. Possible exhaust fan problem. m) Drive(x) Drive voltage disabled. Not input voltage source to Drive(x). n) Drive(x) Drive configuration invalid. Drive(x) has lost factory drive configuration. o) Surface Fire. The surface fire suppression system has activated. p) COMM(x) Fault: Drive(x) has no communication. Drive(x) CAT5 is probably not connected to

Truflow. q) COMM2 Port Error: The CAT5 to all drives is not connected to the Truflow. r) J-Couple Cable Trouble: The J-couples are not connected to the Truflow.

Drive Faults and Errors:

a) Drive in SLF state: Drive(x) is not communicating with the Truflow. b) Drive in NST state: Drive(x) is communicating but no information is being sent by Truflow.

Typical fault displayed on diagnostic screen after MODbus, Comm Port or Comm fault.

Typical fault displayed on DASHBOARD screen after surface fire suppression activates.


18

The Report Screen

From the DASHBOARD press the Report button.

The reports available are listed on the screen. Press any bar to view the reports named.

YTD Cost of Gas

The YTD Cost of Gas report is a chart of the cost of gas in dollars vs. the month of the year for all kitchens connected to Truflow. The first month of the year is the month the Truflow was commissioned. The cost of gas includes the cost to heat the kitchen makeup air unit that is replacing the kitchen exhaust during winter operation.

The yearly accumulative gas cost is shown just above the Company Name on the lower left side of the chart.

YTD Cost of Electricity

The YTD Cost of Electricity report is a chart of the cost of electricity in dollars vs. the month of the year for all kitchens connected to Truflow. The first month of the year is the month the Truflow was commissioned. The electricity cost includes the cost to run any motor connected to the Truflow and the cost to air condition the kitchen during the summer from a DX or chilled water makeup air unit.

The yearly accumulative electrical cost is shown just above the Company Name on the lower left side of the chart.


19

Daily Cost of Utilities

The Daily Cost of Utilities report is a chart of the daily cost of gas and electricity in dollars vs. the day of the week for all kitchens connected to Truflow. The first day of the week is the day the Truflow was commissioned. The electricity cost includes the cost to run any motor connected to the Truflow and the cost to air condition the kitchen during the summer from a DX or chilled water makeup air unit. The cost of gas includes the cost to heat the kitchen makeup air unit that is replacing the kitchen exhaust during winter operation.

% Time in Override

The % Time in Override graph plots the percentage of time in override vs. the total time of operation. If the percentage time in override exceeds 20% call an authorized Spring Air Systems service technician to adjust the Truflow Override Sensitivity range with the Truflow.

% Time Exceeding Goal

The % Time Exceeding goal graph plots the percentage of time you have exceeded your goal vs. the total time of operation. If the value is above zero you are exceeding your annual goal reduction.


20

KES Users Screens (Optional)

When a Spring Air Systems commercial kitchen Enviro (KES) unit is installed in the exhaust ductwork in conjunction with the kitchen exhaust hoods the DASHBOARD incorporates a Pre Filter, Bag Filter and Box

Filter status button. The KES unit is designed to remove grease and particulates from the kitchen exhaust air in accordance to the UL1978 standard for commercial kitchen exhaust. The grease and particulates are removed with three particulate filters located in the KES unit. These filters will clog with particulate and grease and must be replaced from time to time. The Enviro Status button informs the user the

condition of each of the three filters. Green indicates the filter is OK. Yellow indicates the filter is nearing the end of the filters useful life and will require replacing shortly. Red indicates the filter is about to clog and must be replaced as soon as possible. Filter Annunciation:

Press the Enviro Status button on the DASHBOARD and the Enviro Status screen appears.

The first bar indicates the amount of the Pre Filter that has been used. The yellow area is the used portion of the Pre Filter and the green area above the yellow area is the portion left. In this case the Pre Filter has about 20% usage left. The 0.61 value is the pressure drop in inches W.C. across the filter.

The second bar indicates the amount of the Bag Filter that has been used. The bright green area is the used portion of the Bag Filter and the green area above the bright green area is the portion left. In this case the Bag Filter has about 80% usage left. The 0.31 value is the actual pressure drop in inches W.C. across the filter.

The third bar indicates the amount of the Box Filter that has been used. The bright green area is the used portion of the Box Filter and the green area above the bright green area is the portion left. In this case the Box Filter has about 90% usage left. The 0.21 value is the actual pressure drop in inches W.C. across the filter.


21

Odor Spray Unit (Optional)

When the Spring Air Systems Enviro (KES) unit has an optional Odor Spray unit mounted on the KESF fan section or in the ductwork, this box will appear on the top left of the Enviro status screen. Press the green box to set the Odor Spray timers.

The Odor Spray has two timers: Cycle Timer and Duration Timer. The Cycle Timer is the time in minutes between spraying. The Duration Timer is the time in seconds of the actual spray. Press the Cycle Timer box to open the Truflow number keypad. Select the desired length of the Cycle timer and press Enter to return to the Odor Spray timer screen.

Press the Duration Timer box to open the Truflow number keypad. Select the desired length of the Duration timer and press Enter to return to the Odor Spray timer screen.

TRUFLOW Wash Screens (Optional)

The Truflow Wash panel can be supplied with up to three wash sequence. To set each wash delay and wash time, press the Setup button on the DASHBOARD. STANDARD DASHBOARD DASHBOARD with KES


22

Setup screen

From the setup screen press the Water Droplet button. If there is no water droplet on the setup screen the Truflow has not been factory set to include activating wash panels. Call Spring Air for details to setup the wash function.

Wash Sequence 1 The Wash Delay and Wash Timer screen appears. If the Truflow has only one wash sequence leave Sequence 2 and Sequence 3 Delay and Wash timers at 0.

To set Sequence 1 Wash Delay press the green box below Delay.

To set Sequence 1 Wash time press the green box below Wash. After the Delay and Wash times have been entered press the OK button to resume setup.

To check the wash settings from the DASHBOARD press the System Control button.

Activating the Wash Turn the Main Kitchen on. Turn the Main Kitchen off.

The exhaust and supply fan shut off and after the Delay time set above the WASH 1 will start for the length of time set above.


23

KES DASHBOARD in WASH Mode:

After the Wash Delay time is entered above, the Exhaust CFM button will change to a water droplet with the number 1 above.

Standard DASHBOARD in WASH Sequence 1: After the Wash Delay time is entered above the Exhaust CFM button will change to a water droplet with the number 1 above.

Standard DASHBOARD in WASH Sequence 2 After the second Wash Delay time is entered above the Exhaust CFM button will change to a water droplet with the number 2 above.

If zero was entered for the second Wash Delay and second Wash time there is no second wash.

Standard DASHBOARD in WASH Sequence 3 After the third Wash Delay time is entered above the Exhaust CFM button will change to a water droplet with the number 3 above.

If zero was entered for the third Wash Delay and third Wash time there is no third wash. Once all the washes have completed, the Truflow panel will remain idle until the next time the kitchen is turned on from the Systems Control screen, from the Automatic open and close time settings or through the RSS on override.


24

TRUFLOW TOUCHSCREEN STARTUP REPORT

BEFORE ATTEMPTING TO SERVICE THE VARIABLE SPEED DRIVES PLEASE READ APPENDIX J CAREFULLY.

General Information

Spring Air Service Company

Job Name Date Customer Location Truflow Model No. Number of Kitchens (1 to 4)

Kitchen One Total Exhaust CFM Number of Hoods connected Number of Exhaust Drives Connected Exhaust Drive 1 HP Voltage Exhaust Fan 1 Manufacturer Model No. Exhaust Drive 2 HP Voltage Exhaust Fan 2 Manufacturer Model No. Exhaust Drive 3 HP Voltage Exhaust Fan 3 Manufacturer Model No. Exhaust Drive 4 HP Voltage Exhaust Fan 4 Manufacturer Model No. Exhaust Drive 5 HP Voltage Exhaust Fan 5 Manufacturer Model No. Exhaust Drive 6 HP Voltage Exhaust Fan 6 Manufacturer Model No. Total Supply CFM Supply Fan Manufacture Model No. Supply inlet 10 feet from exhaust a Supply Drive 1 HP Voltage b Supply control signal (4-20

milliamps) Low setting High Setting

Information supplied by Spring Air Systems


25

Kitchen Two Total Exhaust CFM Number of Hoods connected Number of Exhaust Drives Connected Exhaust Drive 1 HP Voltage Exhaust Fan 1 Manufacturer Model No. Exhaust Drive 2 HP Voltage Exhaust Fan 2 Manufacturer Model No. Exhaust Drive 3 HP Voltage Exhaust Fan 3 Manufacturer Model No. Exhaust Drive 4 HP Voltage Exhaust Fan 4 Manufacturer Model No. Exhaust Drive 5 HP Voltage Exhaust Fan 5 Manufacturer Model No. Exhaust Drive 6 HP Voltage Exhaust Fan 6 Manufacturer Model No. Total Supply CFM Supply Fan Manufacture Model No. Supply inlet 10 feet from exhaust a Supply Drive 1 HP Voltage b Supply control signal (4-20



Kitchen Three Total Exhaust CFM Number of Hoods connected Number of Exhaust Drives Connected Exhaust Drive 1 HP Voltage Exhaust Fan 1 Manufacturer Model No. Exhaust Drive 2 HP Voltage Exhaust Fan 2 Manufacturer Model No. Exhaust Drive 3 HP Voltage Exhaust Fan 3 Manufacturer Model No. Exhaust Drive 4 HP Voltage Exhaust Fan 4 Manufacturer Model No. Exhaust Drive 5 HP Voltage Exhaust Fan 5 Manufacturer Model No. Exhaust Drive 6 HP Voltage Exhaust Fan 6 Manufacturer Model No. Total Supply CFM Supply Fan Manufacture Model No. Supply inlet 10 feet from exhaust a Supply Drive 1 HP Voltage b Supply control signal (4-20




26

Kitchen four Total Exhaust CFM Number of Hoods connected Number of Exhaust Drives Connected Exhaust Drive 1 HP Voltage Exhaust Fan 1 Manufacturer Model No. Exhaust Drive 2 HP Voltage Exhaust Fan 2 Manufacturer Model No. Exhaust Drive 3 HP Voltage Exhaust Fan 3 Manufacturer Model No. Exhaust Drive 4 HP Voltage Exhaust Fan 4 Manufacturer Model No. Exhaust Drive 5 HP Voltage Exhaust Fan 5 Manufacturer Model No. Exhaust Drive 6 HP Voltage Exhaust Fan 6 Manufacturer Model No. Total Supply CFM Supply Fan Manufacture Model No. Supply inlet 10 feet from exhaust a Supply Drive 1 HP Voltage b Supply control signal (4-20


Information supplied by Spring Air Systems Startup Procedure Item Description Y / N 1 Turn off all Cooking equipment. 2 Disconnect power to the Truflow

Check Truflow Panel Connections prior to startup 3 Check that all VFD CAT5 cable is connected to drives. Each drive CAT5 is connected

in series starting from Truflow VFD.

4 Check that Outdoor Temperature Transducer CAT5 is connected. 5 Install J-Couple cable with mini-clips from Truflow to each hood duct collar connected

to Kitchen1.

Install J-Couple cable with mini-clips from Truflow to each hood duct collar connected to Kitchen2.

Install J-Couple cable with mini-clips from Truflow to each hood duct collar connected to Kitchen3.

Install J-Couple cable with mini-clips from Truflow to each hood duct collar connected to Kitchen4 .

6 Check that CAT5 internet cable is connected to Truflow. 7 Check that LON is connected to Truflow. 8 If there are no wires on terminals D+L, jumper these terminals (1st Kitchen).

If there are no wires on terminals D2+L2, jumper these terminals (2nd Kitchen). If there are no wires on terminals D3+L3, jumper these terminals (3rd Kitchen).

If there are no wires on terminals D4+4L, jumper these terminals (4th Kitchen).


27

Check Exhaust Fan Drives 9 Turn power off to all exhaust fan drives at breaker panel. 10 Exhaust Drive 1: Check that drive connected is powered from breaker panel and

connected to Drive 1 terminals L1,L2,L3.

Exhaust Drive 2: Check that drive connected is powered from breaker panel and connected to Drive 2 terminals L1,L2,L3.





11 Exhaust Drive 1: Check that drive connected is connected to exhaust fan disconnect from Drive 1 terminals U1,U2,U3.

Exhaust Drive 2: Check that drive connected is connected to exhaust fan disconnect from Drive 2 terminals U1,U2,U3.





12 Check that each exhaust fan disconnect switch is in on position and that fan discharge is free and clear.

Check Supply Fan Drives

13 Turn power off to all supply fan drives at breaker panel. 14 Supply Drive 1: Check that drive connected is powered from breaker panel and

connected to Drive 1 terminals L1,L2,L3.

Supply Drive 2: Check that drive connected is powered from breaker panel and connected to Drive 21 terminals L1,L2,L3.

15 Supply Drive 1: Check that drive connected is connected to exhaust fan disconnect from Drive 1 terminals U1,U2,U3.

Supply Drive 2: Check that drive connected is connected to exhaust fan disconnect from Drive 2 terminals U1,U2,U3.

Truflow Panel Operation

16 Turn power on to all drives at breaker panel 17 Check that all drives display Nst or Rdy. 18 Turn power on to the Truflow panel and confirm 120V across terminals 1 + 4. 19 Press the Setup icon to go to Setup screen for temperatures. Outside Temp (F) Kitchen Temp (F) 20 Once the DASHBOARD appears press the Systems Control icon 21a Kitchen 1: Press the Fan on button. Check rotation of all fans.

Kitchen 2: Press the Fan on button. Check rotation of all fans. Kitchen 3: Press the Fan on button Check rotation of all fans.

Kitchen 4: Press the Fan on button Check rotation of all fans. 22 Login to Truflow as the Administrator through Setup screen.


28

Truflow Panel Operation Continued 23 Check the parameters as viewed from Setup screen selecting each Kitchen. 24 Exh. Drive 1 Kitchen # HZ

Amps Line Voltage Exh. Drive 2 Kitchen # HZ Amps Line Voltage Exh. Drive 3 Kitchen # HZ Amps Line Voltage Exh. Drive 4 Kitchen # HZ Amps Line Voltage Exh. Drive 5 Kitchen # HZ Amps Line Voltage Exh. Drive 6 Kitchen # HZ

Amps Line Voltage 25 Supply Drive 1 Kitchen # HZ

Amps Line Voltage Supply Drive 2 Kitchen # HZ

Amps Line Voltage 26 Go to System Control screen and set Override time

Press O/R for Kitchen 1 Override Time Press O/R for Kitchen 2 Override Time Press O/R for Kitchen 3 Override Time

Press O/R for Kitchen 4 Override Time 27 Return to DASHBOARD and press Efficiency button for each Kitchen

Kitchen 1 Screen CFM All drives to maximum HZ Kitchen 2 Screen CFM All drives to maximum HZ Kitchen 3 Screen CFM All drives to maximum HZ

Kitchen 4 Screen CFM All drives to maximum HZ 28 Turn on all appliances. Check that CFM increases 29 Once all appliances are on and hot, check that each drive HZ is at maximum. 30 Very slowly reduce the PXR set point until drive HZ falls from maximum value. This

may take 15 minutes in total.

Kitchen 1 PXR set point Kitchen 2 PXR set point Kitchen 3 PXR set point

Kitchen 4 PXR set point 31 From System Control screen turn canopy light off and on for each Kitchen. Check for

120V between terminal 4 + 6.

32 Spring Air SAT variable speed supply unit Check that wiring is complete between all terminals. 33 Spring Air SFT indirect gas fire unit 3 Check that wiring is complete between all terminals. Comments:

Service Technician:_____________________________________________________________ Company:_____________________________________________________________

Yes I have received a set of Spring Air Systems Inc. maintenance manuals. Signature ___________________ Print Name ____________________


29

APPENDIX APPENDIX A. Truflow stainless steel enclosures dimensions Hood mounted.

Wall Mounted.

TRUFLOW enclosure wall mounted Figure 14

TRUFLOW enclosure, hood mounted Figure 13


30

APPENDIX B. Remote Wiring

TRUFLOW Control panel wiring schematic One Kitchen Figure 15


31

TRUFLOW Control panel wiring schematic Two Kitchens Figure 16


32

TRUFLOW Control panel wiring schematic Three Kitchens Figure 16


33

TRUFLOW Control panel wiring schematic Four Kitchens Figure 17


34

APPENDIX C PXR Factory Setup Set Point (SV parameter) - Factory setting ONE Duct Collar SV=70 Press SEL once. Use \/ and /\ to adjust the set point to 70. Press SEL.

The factory setting is 70F.

PXR3: Factory setup Power the Truflow panel and proceed to input the following setting.

2nd Block Parameters Press SEL and hold for about 3 seconds until P appears on the display. Release SEL. P=28

Press SEL again to set the Proportional Band. Use the /\ to increase parameter set value and \/ to decrease parameter set value. Set P = 28 and then press SEL.

[=0 Press \/ to next parameter, integral time, [. Press SEL and set value to 0. Press SEL. d=0 Press \/ to next parameter, derivative action time, d. Press SEL and set value to 0. Press SEL. hys=0 Press \/ to next parameter, hysteresis, hys. Press SEL and set value to 0. Press SEL. CTrL=PID Press \/ three times to next parameter, Control algorithm, CTrL. Press SEL and check that the

setting is PID. If is not use the \/ and /\ to set to PID and then press SEL. P-n2=2 Press \/ three times to next parameter, input type code, P-n2. Press SEL and adjust setting to 2.

Press SEL. P-SL=55 Press \/ to next parameter, Lower limit of input range, P-SL. Press SEL and adjust setting to 55.

Press SEL. P-SU=200 Press \/ to next parameter, Upper limit of input range, P-SU. Press SEL and adjust setting to 200.

Press SEL. ALN1=1 Press \/ fiver times to next parameter, Type of alarm 1, ALN1. Press SEL and adjust setting to 1.

Press SEL. Press SEL and hold for about 2 seconds to return to set point. 3rd Block Parameters Press SEL and hold for about 5 seconds until P-n1 appears on the display. Release SEL. P-n1=3 Press SEL again to set the Control Action, P-n1. Use the /\ and \/ to adjust the value to 3. Press

SEL. SV-L=55 Press \/ to next parameter, Lower limit of SV, SV-L. Press SEL and adjust setting to 55. Press

SEL. SV-H=120 Press \/ to next parameter, Upper limit of SV, SV-H. Press SEL and adjust setting to 120. Press

SEL. Press SEL and hold for about 2 seconds to return to set point. 1st Block Parameters Press SEL and hold for about 1 second until STbY appears on the display. (or LACH)

AT=1 Press \/ until AT appears on display. Press SEL and set the Auto-tuning to 1. using \/ and /\. Press

SEL. AL1=90 Press \/ three times until AL1 appears on the display. Press SEL and set the Alarm1 set value to

90. Press SEL. StbY Set to off. Prog Set to off.


35

APPENDIX D. PXR Sensor fault Operation


36

APPENDIX E TELE FACTORY DRIVE TERMINAL SCHEMATIC

DRIVE TECHNICAL SPECIFICATIONS FOR LOCATING DRIVE PANELS


37

APPENDIX F HAZARDOUS WARNING


38

APPENDIX G GOOD WIRING PRACTICE


39

APPENDIX H GROUNDING


40

APPENDIX I STARTING THE DRIVE MANUALLY


41

APPENDIX J ACCESSING THE DRIVE PROGRAM MENU


42

APPENDIX K

SPRING AIR SYSTEMSTRUFLO - TELE PROGRAMMED PARAMETERS TOUCHSCREEN

CODE LONG LABEL SAS VALUE DRC - SETTINGS

BFR Std. Motor Frequency 60Hz NCR Motor Full Load Amps DEFALUT (TRUFLO) -- +10%(KES) TFR Max Frequency 72Hz

SET - SETTINGS ACC Acceleration ramp time 10.0s [35.0s - SAT Unit] DEC Deceleration ramp time 10.0s [35.0s - SAT Unit] LSP Low Speed 18Hz (TRUFLO) -- 48Hz (KES) HSP High Speed 60Hz (TRUFLO) -- 65Hz (KES) TTD Motor Thermal threshold 118%

CTL - Command FR1 Configuration reference1 REFERENCE VIA MODBUS LAC Function Access Level L3

FUN - Command SA1 Summing Inputs SA2 SA2 Summing Input 2 no SA3 Summing Input 3 no

PS2 Preset speed Bit 13 MODbus / Canopen

PS4 Preset speed Bit 14 MODbus / Canopen

FLT - Behavior ATR Automatic Restart Yes DRN Derating for Undervoltage Yes OPL Motor phase loss No

CON -SETTINGS ADD Drive Address Value between 2-7 depends on fan TFO MODbus Comm Format 8n1: 8 data bit, no parity, 1 stop bit

ADCO CANopen drive address set to 0

Parameter list based on ALTIVAR 31 for Spring Air - TRUFLO with TOUCH SCREEN Listed parameters entered in VFD keypad display. Press ENT until DRC ( first parameter block ) is displayed. Follow parameter blocks in order as it appears. Once done press ESC until RDY is displayed. Program is complete.


43

APPENDIX L DRIVE MAINTENANCE AND TROUBLE SHOOTING


44


45


46


47


48

APPENDIX M THE WIRELESS REMOTE OPTION


49


50


51

APPENDIX N J-COUPLE REMOTE FACTORY SUPPLIED CABLE


52

APPENDIX O CODE CHANGES The National Fire Protection Association, NFPA-96 2001, code changed to provide for a reduction of the exhaust air from a commercial kitchen during low demand periods. The minimum duct velocity in the NFPA-96 2001 has been reduced from 1500 fpm to 500 fpm. In addition the International Building Code, IBM, was change in 2003 to allow for the reduction in exhaust from a commercial kitchen during low demand periods. The building and fire departments have these codes in their possession and will have no reason not to allow a Truflow installation anywhere in North America.

SIZING THE EXHAUST DUCTWORK We recommend that the engineer size the exhaust ductwork for 1670 fpm velocity. The NPFA-96 code allows for a reduction in duct velocity to 500 fpm. By sizing the ductwork at 1670 for 100% exhaust and duct velocity will be 500 fpm at 30% exhaust volume.

NFPA-96, 2001 8.2 Airflow 8.2.1 Air Velocity 8.2.1.1 The air velocity through any duct shall be not less than 152.1m/min (500 ft/min)

International Mechanical Code. 2003 Section 507 Commercial Kitchen Hoods 507.1 General Exceptions: 3. Net exhaust volumes for hoods shall be permitted to be reduced during no-load cooking conditions, where engineered or listed multi-speed or variable-speed controls automatically operate the exhaust system to maintain capture and removal of cooking effluents as required by this section.


53

APPENDIX P TESTING TRUFLOW AFTER RUNNING FOR 30 SECONDS The unit tested is a KES with supply VSD. 1. Pull the VSD Cat5 from top of panel jack.

a. Unit shuts down b. ERROR: Comport2 Error/Com1 Fault/Com6 Fault after 30 seconds c. Plug the VSD Cat5 back into jack. d. Go the Error Status screen e. Press “Clear Error on Drive button on top right of screen unit errors above disappear. f. Start the unit from Power screen.

2. Pull the J-couple from top of panel jack.

a. Unit continues to run on high b. ERROR: J-Couple cable trouble c. Plug the J-Couple back into panel and error automatically clears.

3. Pull the outdoor air sensor Cat5 from top of panel jack.

a. The outdoor air temperature reading on the DASHBOARD reads -30F. b. Plug the outdoor air sensor Cat5 back into panel.

KES Truflow units only 4. Pull the LV1 Cat5 out of top of panel jack.

a. Unit continues to run. b. ERROR: LV1 Cable Fault c. Plug the LV1 Cat5 back into top of panel.

5. Pull the LV2 Cat5 out of the top of panel jack.

a. KES unit shuts off. b. ERROR: High Temp KES c. Plug the LV2 Cat5 back into jack. d. Press “Clear Error on Drive button on top right of screen unit errors above disappear e. Unit starts to run.


54

APPENDIX Q Adding or Removing Users and Changing Passwords. (Available to Administrator only)

Press the Setup button.

Administrator must login to see the SECURITY BUTTON After administrator login press the Security button

The Password screen appears

Press the down arrow beside Administrator.

Select User and the Truflow keyboard screen appears. Type the new user name. Press Enter when you are done. Touch the box beside Pwd and add the new user password. Press the box beside Confirm Pwd and enter the user password again.

Press the + button to add the user:

Press the arrow button to add the user password:

Press the door to close the screen:

To remove a user, select the user and press the X button:


55

APPENDIX R Truflow Factory Setup: Login as Administrator. If you do not have the Administrators password call Spring Air Systems Inc. head office Service Manager.

Press the Setup button.

Press the Secondary Setup Button

Press the Kitchen Setup bar from the Secondary Setup screen.

Select the number of kitchens connected to the Truflow. Truflow provides a maximum of four independent kitchens.

Press the UP button to increase the number of kitchens. Press the DOWN button to decrease the number of kitchens.

Check the KES box if the Truflow is operating a Spring Air KES unit

Press the RSS button if the Truflow operation will be controlled by a remote dry contact across terminals C+L. If this is not checked the Truflow will operate from the System Control screen and the Automatic open and close settings.


56

Check the Wash box for each kitchen if the Kitchen is connected to Spring Air water wash hoods.

Exhaust Fan Supply Fan

Select the number of exhaust drives on each Kitchen by press the UP button to add drives. Press the DOWN button to remove drives.

Select the type of supply control for each kitchen. If the Truflow is controlling a supply fan with a Variable Speed Drive select the press the box to change screen to VSD. If the supply control requires a 4-20 milliamp signal press the box to change the screen to 4-20 milliamps.

When 4-20 milliamp supply has been selected

Press the 4-20mA to open the Kitchen Input/Output screen.

The 4-20 milliamps can be adjusted to suit the application by adjusting the output signal.

Press the box beside Set Min and Set Max. A Truflow key pad appears to change the Min and

Max to the required high and low for the application.

The Actual Input is the signal generated by the Truflow. The Actual Output is the signal send from the Truflow.

Press OK to return to Setup screen.


57

Press the RESET button to reset all screen Reports to zero. This does not affect the data on the Truflow Compact Flash Card. The Card must be removed to be deleted.

Press the box to select the electrical alternating current correction factory. The value is normally between 0.9 and 1.0. This will affect you electrical reports.

Press the box to select the Coefficient of Performance for the air DX or Chilled Water conditioning systems cooling the Truflow kitchen.

Press to return to Primary Setup screen.

Other Fine Products From SPRING AIR SYSTEMS...

• Water Wash Ventilators ♦ Hot Water Wash ♦ Cold Water Spray/Hot Water Wash ♦ Water Wash Control Panels

• Dry Extractor Hoods

• REV-LOW Hoods

• Cartridge Hoods

• Filter Hoods

• Surface Fire Suppression

• Commercial Kitchen Exhaust Fans

• Kitchen Enviro Systems

♦ KES - 100% Exhaust

• Commercial Kitchen Supply Units

• Compensating Hoods

• Exhaust Fans

• Supply Fans

• Commercial Kitchen Control Panels

• Truflo & Melink Variable Speed Exhaust/Supply Systems

• Utility Distributions Systems Phone: 905-338-2999, FAX: 905-338-1079, e-mail [email protected]

www.springairsystems.com

truflow operation and maintenance manual€¦ · “see what you save” introduction thank you for...

Documents